MSMBLIC002
Licence to operate an advanced boiler


Application

This unit specifies the outcomes required to operate an advanced boiler safely. This includes boiler start-up, handover, monitoring, shutdown and storage of a boiler.

This unit also covers the preparation for inspection procedures as specified in manufacturer recommendations, identification of maintenance requirements and relevant risk control measures.

This unit is based on the licensing requirements of Part 4.5 of the Model Work Health and Safety (WHS) Regulations, High Risk Work, and meets Commonwealth, state and territory high risk work licensing requirements. Any alteration to the unit content or outcomes would result in a unit that is not acceptable to WHS/Occupational Health and Safety (OHS) regulators for the purpose of licensing.


Elements and Performance Criteria

Elements describe the essential outcomes

Performance criteria describe the performance needed to demonstrate achievement of the element

1

Plan and prepare for work

1.1

Follow standard operating procedures (SOPs)

1.2

Comply with work health and safety (WHS) requirements at all times

1.3

Identify potential workplace hazards and appropriate risk control measures consistent with appropriate standards to ensure the safety of personnel and equipment

1.4

Locate and review appropriate records to prepare for boiler operation

1.5

Identify the type of boiler with associated equipment and plan boiler operations according to procedures

1.6

Identify appropriate personal protective equipment (PPE) in accordance with SOPs

1.7

Identify suitable communication methods and confirm with appropriate personnel

2

Start up boiler

2.1

Apply risk prevention and risk control measures to the work area according to procedures

2.2

Select communication equipment and inspect for serviceability

2.3

Select all necessary equipment and inspect for operational effectiveness according to procedures, including establishing water level

2.4

Check boiler and associated equipment visually for any damage or defects and report and record any found according to procedures with appropriate action taken

2.5

Vent boiler to atmosphere prior to start-up, as required

2.6

Carry out pre-start up checks on the boiler and bring the boiler and associated equipment online safely according to procedures

2.7

Start up boiler according to procedures

2.8

Identify maintenance requirements and any visual faults and report according to procedures

2.9

Confirm, complete and log all maintenance and/or repairs and associated isolations and make the equipment serviceable

3

Monitor boiler operation

3.1

Diagnose operating status of the boiler and associated equipment

3.2

Maintain operating log clearly and accurately according to procedures

3.3

Monitor boiler, valves, fittings, pressure gauges combustion management systems, air heaters, superheaters and economisers (where fitted) according to procedures

3.4

Blow boiler water level gauges through both steam and water sides

3.5

Test standby plant and equipment according to procedures

3.6

Conduct boiler water quality tests, where required, and record the results according to procedures

3.7

Adjust boiler water chemicals after tests, where appropriate and required, according to procedures and notify downstream users, if necessary

3.8

Activate the automatic blowdown and, where required, boiler is blown down to adjust total dissolved solids (TDS) levels to recommendations

3.9

Communicate handover information regarding boiler status and associated equipment and operation clearly to relevant personnel according to procedures

3.10

Respond immediately to any boiler emergency in accordance with procedures

4

Shut down boiler

4.1

Shut down the boiler and associated equipment for inspection according to procedures, as required

4.2

Identify maintenance requirements and report any visual faults according to procedures

4.3

Clean boiler and associated equipment internally and externally to manufacturer recommendations and procedures, where required

4.4

Complete isolations associated with in-service maintenance according to procedures

4.5

Complete boiler operating log for shutdown

5

Store boiler in shutdown mode

5.1

Identify storage time and condition of storage, where required

5.2

Store boiler and associated equipment in safe condition for access in accordance with manufacturer recommendations and procedures

5.3

Test stored boiler water and chemicals, where required, and handle in accordance with procedures, where storage is for extended periods

Evidence of Performance

Evidence of competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria, and include demonstration of:

following work instructions, SOPs and safe work practices

complying with Commonwealth, state and territory work, health and safety (WHS) legislation and regulations

complying with Australian and industry standards, organisation workplace standards, policies, relevant codes of practice requirements at all times

planning and preparing for work, including identifying potential hazards and implementing appropriate risk control measures

identifying the type of standard or advanced boiler and associated equipment

reading and interpreting maintenance records, operating logs and safety data sheets (SDS)

conducting the appropriate pre-start up checks, including identifying all maintenance requirements and visual faults

using appropriate tools, equipment and PPE in accordance with procedures

completing all maintenance and rectification requirements in accordance with manufacturers’ and workplace procedures, including recording/reporting requirements

completing the start-up procedures and bringing the boiler online

monitoring the boiler and associated equipment, including conducting relevant tests and activities and adjusting boiler water quality in accordance with procedures

interpreting advanced boiler operation tables and figures

communicating handover of boiler status and associated equipment to appropriate personnel

demonstrating emergency operating procedures

identifying all boiler energy sources required to be isolated and made safe for maintenance, inspection and repairs

applying advanced boiler cleaning and storage techniques.


Evidence of Knowledge

Evidence must be provided that demonstrates knowledge of:

safe work practices and procedures and use of PPE

Commonwealth, state and territory WHS/OHS legislation and approved codes of practice relevant to standard and advanced boiler operation

Australian and industry standards relevant to standard and advanced boiler operation

basic principles of heat transfer and thermodynamics in relation to standard and advanced boiler operation

standard and advanced boiler operation steam equipment operating principles and operating methods

types and characteristics of multiple fuel systems for standard and advanced boilers

types and characteristics of feedwater systems and treatment, including de-aerator

types and use of equipment and fittings for operation and maintenance of boilers

function, purpose and operation of the following:

pre-heater

superheater

economiser

air heater

feedwater heater

attemperator

superheater safety valves

economiser relief valves

main steam stop valve

standard and advanced boiler and auxiliary equipment characteristics and capabilities

essential fittings required where more than one boiler is installed (e.g. battery of boilers)

processes for confirming operational status of a boiler

workplace communication techniques and procedures

responsibilities for checking and testing advanced boilers

location and inspection procedures and techniques for inspection and explosion doors

steam and boiler hazards for cold start and handover

hierarchy of risk control

type and limitations of corrective action and/or adjustments that can be made in response to routine boiler operation problems and emergencies

various harmful energy sources in standard and advanced boiler operation and the means to effectively isolate these energy sources and make them safe with particular consideration to advanced boilers

modes of standard and advanced boiler storage and procedures for storing boiler in open or closed condition

SDS and safe chemical handling and storage methods for boiler operation and cleaning

procedures for cleaning boilers internally and externally, where required

procedures for recording, reporting and maintenance of workplace records and information.


Assessment Conditions

Assessments must be conducted by an assessor accredited for this high risk work (HRW) licence class in the Commonwealth/state/territory where the licence will be obtained (i.e. an assessor authorised by a Commonwealth/state/territory WHS/OHS regulator).

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and all assessments must be conducted in the English language.

Where possible, assessment of performance should be undertaken in the workplace and/or under realistic workplace conditions that typically reflect:

the use of full-scale equipment

performing tasks/activities within timelines that would be expected in a workplace

standard and authorised work practices, safety requirements and environmental constraints.

Where this is not possible or where personal safety, plant operation or environmental damage are limiting factors, assessment must occur in a sufficiently rigorous simulated environment that reflects realistic operational workplace conditions that cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.

Accredited assessors are responsible for ensuring that candidates have access to all tools, equipment, PPE, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications.

As a minimum, assessors must satisfy applicable regulatory requirements, which include requirements in the Standards for Registered Training Organisations (RTOs) current at the time of assessment.


Foundation Skills

This section describes those language, literacy, numeracy and employment skills that are essential to performance.

Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.


Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Boiler includes:

Boilers covered by this unit are standard boilers and advanced boilers, including boilers defined in AS 2593:2004 Safety management and supervision systems and AS 3873:2001 Pressure equipment – Operation and maintenance and typically have a modulating combustion air supply and heat source.

Standard boiler includes:

vessel or an arrangement of vessels and interconnecting parts in which steam and vapour is generated or in which water or other liquid is heated above that of the atmospheric pressure by the application of:

fire

the products of combustion

electrical power

similar high temperature means

fixed and modulating combustion controls, fixed and modulated air supply, a single fuel source and will have:

boiler piping

supports

mountings

valves

gauges

fittings

controls

boiler settings and associated equipment

Advanced boiler includes:

vessel or an arrangement of vessels and interconnecting parts in which steam and vapour is generated or in which water or other liquid is heated above that of the atmospheric pressure by the application of:

fire

the products of combustion

electrical power

similar high temperature means

fixed and modulating combustion controls, fixed and modulated air supply, multiple fuel sources, pre-heaters, superheaters and economisers and will have:

boiler piping

supports

mountings

valves

gauges

fittings

controls

boiler settings and directly associated equipment

Hazards include one or more of the following:

asbestos lagging

chemical hazards

thermal hazards

manual handling hazards

machinery guard requirements

hot exposed steam pipe

leakage of steam

leakage of fuel

odour of gas

fumes from a liquid chemical spill

faulty/broken ladder or hand rail

working at heights

flammable liquids

fire and explosion

electrical hazards

work area, including:

illumination

excessive noise from machinery

spillage of oil

rubbish and combustibles

obstruction

Risk control methods include:

Risk control methods refer to the systematic process of eliminating or reducing the risk to personnel and property through the application of controls.

It includes the application of the hierarchy of control:

elimination

substitution

isolation

engineering controls

administrative controls

personal protective equipment (PPE)

PPE includes one or more of the following:

thermally insulated gloves

hard hat protection

ear protection (muffs or plugs)

chemical resistant gloves and apron

respiratory devices

eye protection

working protective gloves

whole body fire-resistant clothing

Appropriate standards include one or more of the following:

legislation

codes of practice

manufacturer specifications

Australian Standards

technical standards (International)

industry standards (where applicable)

Procedures include one or more of the following:

manufacturer guidelines (e.g. instructions, specifications or checklists)

industry operating procedures

workplace procedures (e.g. work instructions, operating procedures or checklists)

Equipment includes one or more of the following:

gas monitoring equipment

water testing equipment

fire-fighting equipment

workplace first aid equipment

work platform and associated gear, including walkways

Communication methods include one or more of the following:

verbal and non-verbal language

written instructions

signage

hand signals

listening

questioning to confirm understanding

appropriate worksite protocol

Appropriate personnel includes one or more of the following:

production workers

maintenance workers

supervisors and managers

other boiler operators

suppliers

colleagues

Records include one or more of the following:

operating log books

maintenance records

records of faults and potential faults

isolation procedures

safe operating procedures

daily operating inspections

repairs carried out according to manufacturer recommendations and operating procedures

workplace record keeping requirements

details of any daily or periodic maintenance work

details of yearly programmed or additional maintenance work

Risk control measures include one or more of the following:

barricades and controls

machine guarding

fall prevention

pedestrian controls

adequate illumination

noise controls

signage

PPE

Communication equipment includes one or more of the following:

two-way radios

mobile phones

intercoms

landline telephones

pagers

satellite phones

computers

Pre-start up checks include:

testing warning lamps or visual warning indicators

control panel checks

checks of feedwater supply system

fuel supply/heat source systems

operation and position of boiler valves

combustion air supply system

boiler water level

essential fittings and gauges

selection of personal protective equipment

inspection and location of inspection and explosion doors (where applicable)

identification of hazards and management of risks and maintenance problems

fire-fighting equipment

manufacturer recommendations and checklists

relevant records and logs

Associated equipment includes one or more of the following:

multiple fuel sources

pre-heater

superheater

economiser

superheater safety valves

economiser relief valves

air heater

feedwater heater

attemperator

main steam stop valve

Start-up includes:

purge boiler furnace

heat input

warm-up reticulation system

venting the boiler of air, as required

steam traps and steam line purge system operations

reticulation line pressure

steam usage and supply

superheater

air heater

feedwater heater

economiser

Maintenance includes:

leaking steam pipe

pressure gauge accuracy

exposed electrical wiring

defective illumination in the workplace

leaking fuel pump gland

leaks in high pressure feed line

leaking gauge glass mounting

leaking safety valve

isolation procedures, hardware and equipment

Faults include one or more of the following:

abnormal operating conditions

boiler tube failure

feedwater supply and/or other major auxiliary loss

wet steam

high dissolved oxygen

pH of water

high conductivity

actuator or valve mechanical or electrical fault/failure

instrument failure

steam leak

associated equipment failure

Diagnosed includes one or more of the following:

senses, including:

audio

smell

touch

visual

remote or local indicators and recorders

computers and alarms, including:

visible

audible

Operating log includes:

date and time of checking

each check, examination and results

printed and signed name of person who performed the checks

date and time of any lockout or equipment malfunction

results of tests on boiler or feedwater

changes in operation

Valves and fittings include one or more of the following:

safety valves

gauge glasses

main steam stop valve

feedwater stop valve

feed check valve

blowdown valve

steam side/line drain valves

flame failure detection device

water level controller

boiler steam pressure gauge

economiser relief valve

superheater safety valve

Monitored includes:

water supply system

checks of steam reticulation line pressure

usage and supply of steam

quality of steam

combustion/heat source system and management

feedwater system and condensate returns

fuel system

combustion air supply

water level

boiler steam pressure

boiler and steam manifold valves

soot blowers

operation of control/safety devices, including control panels

Tested includes one or more of the following:

response checks

standby plant ‘cut in’ tests

valve operating checks

hydrostatic tests

performance tests

alarm and protection tests

Tests include one or more of the following:

pH levels

conductivity

oxygen

TDS

hardness

other contaminants

Chemicals include one or more of the following:

oxygen scavenger

feedwater additives

other chemicals

hardness

condensate chemicals

pH buffers

Handover includes:

previous load requirements

maintenance issue, including equipment isolated for maintenance

operational incidences

read operating log

general inspection of boiler to detect any defects

accept responsibility of boiler

noted equipment malfunctions

required equipment tests

Emergencies include one or more of the following:

tube failure

loss of water level

power failures

inadequate housekeeping

explosion

fire

bomb threat

terrorism

personal accidents

chemical spills

major steam leaks

major water leaks and flooding

natural disasters

oil spills

Appropriate emergency response measures include one or more of the following:

identification of emergency

isolation of heat source

selection and application of appropriate fire-fighting equipment and PPE

notification of downstream users

operation of boiler only when safe to do so

notification of appropriate regulatory authorities, including Commonwealth, state, territory and boiler manufacturer

Shutdown includes:

checks of water level

cooling down process

valve settings

equipment isolation

boiler pressure/vacuum

fuel/heat source isolation in accordance with manufacturer recommendations

boiler post-purge

Storage mode includes:

wet and dry storing

open or closed position


Sectors

Boiler operation (licensed)